RACKST
AR
RackStar
Manual • 07610-004-33-05-E
INSTALLATION, OPERATION,
AND SERVICE MANUAL
RACKSTAR
SERIES CONVEYOR DISHMACHINES
®
Page 1: ...RACKSTAR RackStar Manual 07610 004 33 05 E INSTALLATION OPERATION AND SERVICE MANUAL RACKSTAR SERIES CONVEYOR DISHMACHINES...
Page 2: ...alled by Jackson at the factory and are shipped with the Dishmachine carry only a 1 one year parts warranty Labor to repair or replace these components is not included in the warranty or covered by Ja...
Page 3: ...RESULTS FROM DEFECTS IN MATERIALS AND WORKMANSHIP AND IS REPORTED TO JACKSON WITHIN 30 THIRTY DAYS FROM THE DATE OF INSTALLATION 9 DAMAGE CAUSED BY LABOR DISPUTE 10 DAMAGES RESULTING FROM IMPROPER CO...
Page 4: ...ed item 12 on pgs 59 and 60 with new part Added Drive Plate components to pg 60 Added communication cable to Display Assembly page Added a Frame Assembly page Replaced item 7 on pg 66 with new part Ch...
Page 5: ...vailable on holidays Contact technical support toll free at 1 888 800 5672 Technical support is available for service personnel only RackStar 44 RackStar 66 Electrically heated rack conveyor machine a...
Page 6: ...tallation Instructions 19 Inspection 19 Unpacking 19 Leveling 19 Adjusting Doors 19 Plumbing 19 Drain Line Connection 20 Steam Line Connection 21 Electrical Power Connections 21 Motor Rotation 22 Vent...
Page 7: ...leshooting 32 Programming 34 Fault Codes 36 PARTS Control Box 38 Display 39 Miscellaneous Electrical Components 40 Wash Heater Shroud 41 Wash Heaters 42 Pump Suction 43 Plumbing 44 Pre wash Fill Plumb...
Page 8: ...69 Booster Heater Electric 70 Booster Heater Add on Kit Electric 71 Frame 72 Doors 73 Energy Recovery System 74 Miscellaneous Options 76 SCHEMATICS 208 230 V 50 60 Hz 3 Phase 77 460 V 50 60 Hz 3 Phas...
Page 9: ...Power Hz Hertz ID Inside Diameter kW Kilowatts MIN Minimum NFPA National Fire Protection Association NPT National Pipe Thread ppm Parts per Million PSI Pounds per Square Inch V Volts 40 40 degree Rise...
Page 10: ...t Standard also uses secondary opening for a separate connection to only the booster LEGEND A Electrical Connection B Main Water Inlet 1 2 NPT 110 F MIN 18 kW Booster 140 F MIN 12 kW Booster or 180 F...
Page 11: ...t Standard also uses secondary opening for a separate connection to only the booster LEGEND A Electrical Connection B Main Water Inlet 1 2 NPT 110 F MIN 18 kW Booster 140 F MIN 12 kW Booster or 180 F...
Page 12: ...Primary Electrical Opening Provided on both ends of machine Secondary Electrical Opening Provided on both ends of machine Single point Option uses only primary opening to power the entire machine Dua...
Page 13: ...tion 3 4 NPT Open Door High Hood Option All dimensions from the floor can be increased 1 3 4 using the machine s adjustable feet Items in red are not supplied with the machine Items in blue are for th...
Page 14: ...F MIN increased 1 3 4 using the machine s adjustable feet Items in red are not supplied with the machine LEGEND Primary Electrical Opening Provided on both ends of machine Secondary Electrical Openin...
Page 15: ...entire machine Dual point Standard also uses secondary opening for a separate connection to only the booster 34 1 4 870 mm TABLE HEIGHT A Electrical Connection B Water Inlet 1 2 NPT 110 F MIN 27 kW B...
Page 16: ...rimary opening to power the entire machine Dual point Standard also uses secondary opening for a separate connection to only the booster A Electrical Connection B Water Inlet 1 2 NPT 110 F MIN 27 kW B...
Page 17: ...to power the entire machine Dual point Standard also uses secondary opening for a separate connection to only the booster A Electrical Connection B Water Inlet 1 2 NPT 110 F MIN 27 kW Booster C Drain...
Page 18: ...23 L R UNHOODED SIDE LOADER 23 R L UNHOODED SIDE LOADER Ventilation Scoop Ventilation Scoop Ventilation Cowl with Cut out for L R Units Dimension is 30 for the 30 unhooded side loader Dimension is 30...
Page 19: ...8 5 8 201 4 W1 S W2 PS PW 33 11 3 8 22 71 2 E E E 11 16 3 8 E Main Electrical Connection 7 8 Hole W1 Main Inlet Water Connection 3 4 NPT 110 F MIN 20 5 PSI W2 Water Outlet Connection 3 4 NPT PW Water...
Page 20: ...5 575 5 575 5 575 5 575 Glasses per Hour 8 028 8 028 8 028 8 028 8 028 8 028 Tank Capacity Gallons RackStar 44 RackStar 66 RackStar 44S RackStar 66S RackStar 44ER RackStar 66ER Wash Tank 25 25 25 25...
Page 21: ...N A N A Minimum Incoming Cold Water Temperature ER Units Only N A N A N A N A 55 55 CHEMICAL SANITIZING Water Temperatures F RackStar 44 RackStar 66 RackStar 44S RackStar 66S RackStar 44ER RackStar 6...
Page 22: ...lts Always verify the amperage draw of the machine in operation when sizing circuit protection If the machine is equipped with a booster heater note the heater has its own electrical connection and th...
Page 23: ...ut notice If using a third party external booster consult booster manufacturer for booster information With dual point connection standard Booster Heater has its own connection Imbalanced wild leg goe...
Page 24: ...ve Motor Wash Heater Total Load MCA MOP 208 3 60 Hz 6 2 A 9 2 A 1 1 A 41 6 A 58 1 A 60 4 A 65 A 230 3 60 Hz 6 2 A 8 6 A 1 1 A 34 6 A 50 5 A 52 6 A 60 A 460 3 60 Hz 3 1 A 4 3 A 0 7 A 17 3 A 25 4 A 26 5...
Page 25: ...A 460 3 60 Hz 4 3 A 0 7 A 17 3 A 32 5 A 54 8 A 55 9 A 60 A Volts Phase Freq Wash Motor Drive Motor Wash Heater Booster Heater Total Load MCA MOP 208 3 60 Hz 9 2 A 1 1 A 41 6 A N A 51 9 A 54 2 A 60 A 2...
Page 26: ...48 2 A 50 A Volts Phase Freq PW Motor Wash Motor Drive Motor Wash Heater Booster Heater Total Load MCA MOP 208 3 60 Hz 6 2 A 9 2 A 1 1 A 41 6 A 33 3 A 91 4 A 93 7 A 100 A 230 3 60 Hz 6 2 A 8 6 A 1 1 A...
Page 27: ...esigned to operate while level This is important to prevent any damage to the machine during operation and to ensure the best results The machine comes equipped with adjustable bullet feet which can b...
Page 28: ...o the proper flow pressure indicated on the data plate The water supply line must be 1 2 NPT minimum and must be able to provide water at the minimum temperature indicated on the machine data plate A...
Page 29: ...ming voltage matches the voltage indicated on the decal next to the incoming power pre punched hole For dual point connection machine has a separate power connection from the rinse booster heater and...
Page 30: ...venting This is essential to permit efficient removal of the condensation exhaust Ensure the exhaust system is acceptable in accordance with applicable codes and standards Any damage caused by steam a...
Page 31: ...ers must be set for the type and concentration of chemicals being used Detergent usage and water hardness are two factors that contribute greatly to how efficiently the machine will operate Using the...
Page 32: ...zer tube connections shown to the right Rinse aid and detergent dispenser connections shown to the right EXHAUST FAN TIMER RED BLK WHT WHT BLK WHT BLK GRY RED YEL RED DETERGENT DISPENSER CONNECTION LI...
Page 33: ...heat necessary to keep energy costs down Note the approximate locations for each type of curtain in the above illustrations See the chart below for actual curtain lengths and part numbers Note the di...
Page 34: ...ode of operation the wash heater will energize Refer to the machine data plate for a better understanding of the minimum temperatures needed to operate the machine correctly It might take several minu...
Page 35: ...hine This machine is designed to wash ware that is placed in a rack Materials should not be placed in the machine unless they are properly secured in a dish rack To start the cycle gently push the rac...
Page 36: ...ank for debris 6 Remove curtains scrub with mild detergent and brush and allow to air dry 7 Wash Rinse Arms a As needed fill the tub with water b Remove the end caps from the arms c Run an empty rack...
Page 37: ...tional 2 The machine will then go into Standby Mode blank display 3 Press the Power Button 4 The display will show Heating until the wash tank reaches operating temperature 5 The display will show Rea...
Page 38: ...mended by the chemical supplier 6 The wash tank holds 25 gallons and pre wash tank holds 15 8 gallons of water After chemicals are added 7 Make sure doors are closed 8 Press Delime Button and run mach...
Page 39: ...r temperature could be too low 2 Ensure all strainers are clean and in place laying flat before operating the machine When cleaning out strainers do NOT beat them on waste cans Wipe out strainers with...
Page 40: ...maged 2 Wash motor contactor faulty 1 Verify that the wash motor is getting power if so replace the motor 2 Check for continuity if contacts are open replace the contactor Dishmachine runs continuousl...
Page 41: ...ce the seal 2 Tighten 3 Tighten the hose clamps Will not rinse 1 Defective rinse solenoid 2 Faulty timer 3 No water to the machine 1 Repair or replace the rinse solenoid 2 Replace timer 3 Verify that...
Page 42: ...buttons Up arrow Down arrow and Select are hidden on the display and are shown below outlined with red dots 1 Press and hold the I and II Buttons until Program starts flashing 2 3 seconds 2 Press the...
Page 43: ...ton to cycle through the categories will be flashing Language Wash Offset Temperature Scale Rinse Offset Wash Temperature Boost Offset Boost Temperature Spare Offset 4 Press the Select Button to choos...
Page 44: ...output from IO module turns off when above the set temperature 2 Substitute a 1 2 k resistor for T1 and verify that wash heater turns off If not replace IO module 3 Verify that T1 resistance is corre...
Page 45: ...33 05 E 37 RESISTANCE TO TEMPERATURE VALUES R k F 11 58 69 8 10 37 75 2 9 30 80 6 7 78 89 6 3 05 140 0 2 54 150 8 2 18 159 8 1 58 179 6 1 45 185 0 1 33 190 4 1 16 199 4 0 96 212 0 FAULT CODES TROUBLE...
Page 46: ...1 I O Module 06401 004 76 12 5 2 Relay 05945 111 72 51 6 1 Timer Universal Digital Multi timer 05945 004 22 78 7 1 Overload See Motor Overloads page 8 2 Contactor Wash Motor 05945 111 68 38 9 1 Overlo...
Page 47: ...5310 002 83 12 2 1 Board Populated Circuit 05945 004 46 18 3 4 Spacer Display Board 05999 004 19 75 4 1 Membrane Switch and Panel Assembly 05700 004 59 65 5 1 Communication Cable 05700 004 33 64 1 Cov...
Page 48: ...930 111 68 44 2 1 Float Switch 06680 121 70 71 3 1 Float Switch Cover 05700 004 71 80 4 1 Probe Fitting Brass 05310 924 02 05 5 1 Thermistor Probe 06685 004 34 58 6 6 Fuse 200 mA Slow acting 05999 004...
Page 49: ...9 4 1 Gasket Pump Suction 05330 003 75 87 5 1 Gasket Heater 05330 200 02 70 6 1 Heater Box Rails 05700 003 74 72 7 1 Wash Pump Suction 05700 003 77 63 8 2 Washer 1 4 20 05311 174 01 00 9 9 Locknut 1 4...
Page 50: ...wash heaters it is highly recommended to change the gasket as well Once installed gaskets become compressed and are subject to extreme temperature changes Replacing the gasket with the heater might p...
Page 51: ...ing 05330 003 75 89 2 1 Gasket Pump Suction 05330 003 75 87 3 1 Pre wash Pump Suction Weldment 05700 003 82 27 4 1 Strainer Pre wash Pump 05700 003 81 28 4 1 3 2 Pump Suction Assembly 05700 003 83 98...
Page 52: ...211 27 00 6 2 Vacuum Breaker 1 2 Brass 04820 003 06 13 7 1 Y Strainer 1 2 04730 217 01 10 8 1 Plug 1 2 Brass Pipe 04730 209 03 00 9 2 Tee 1 2 x 1 2 x 1 4 04730 002 22 56 10 1 Plug 1 4 Brass 04730 209...
Page 53: ...30 207 19 00 7 1 Solenoid Valve 1 2 04810 003 71 55 8 1 Manifold Turbo Rinse Water In 05700 004 38 67 9 1 Fitting Comp 1 2 x 1 4 05700 004 36 74 10 3 Plug 1 8 Brass 04730 209 07 37 11 1 Piping Manifol...
Page 54: ...ld Tank Fill 05700 004 38 64 3 1 Vacuum Breaker 1 2 Brass 04820 003 06 13 4 2 Nipple 1 2 Close Brass 04730 207 15 00 5 1 Solenoid Valve 1 2 04810 003 71 55 6 1 Tee 1 2 x 1 2 x 1 4 04730 002 22 56 7 1...
Page 55: ...old Single point Tubing 05700 004 48 43 7 1 Vacuum Breaker 1 2 Brass 04820 003 06 13 8 1 Y Strainer 1 2 04730 217 01 10 9 1 Plug 1 2 Brass Pipe 04730 209 03 00 Complete ER Fill Plumbing Assembly L R 0...
Page 56: ...ket 05700 004 41 58 6 2 Adapter 1 2 04730 011 59 53 7 1 Pressure Transducer 05945 004 17 01 8 1 Tee 1 2 x 1 2 x 1 4 Female 04730 411 25 01 9 1 Pressure Regulator 04820 100 04 07 10 1 Bracket ER Inlet...
Page 57: ...30 206 08 00 7 1 Rinse Injector L R 05700 003 76 82 1 Rinse Injector R L 05700 003 76 83 8 2 Adapter 1 2 04730 011 59 53 9 1 Fitting Comp 1 2 x 1 4 05700 004 36 74 10 1 Valve 1 2 04810 003 71 55 11 2...
Page 58: ...07610 004 33 05 E 50 1 2 4 5 4 6 7 13 8 9 14 14 10 11 11 10 12 14 13 3 PARTS WASH SYSTEM 16 15 Mechanical Pump Seal 05330 002 34 22...
Page 59: ...72 37 9 1 Upper Wash Manifold 05700 003 73 66 10 1 Wash Arm Top right 05700 003 75 79 11 1 Wash Arm Top left 05700 003 75 80 12 12 Cap Threaded 04730 603 12 00 13 3 O ring Silicone 0 103 Dia 2 1 2 x...
Page 60: ...07610 004 33 05 E 52 Mechanical Pump Seal 05330 002 34 22 PARTS PRE WASH SYSTEM 1 2 3 4 5 6 7 8 9 10 11 12 13 10 5 7 2 8...
Page 61: ...ifold 09515 003 77 22 8 2 O ring Silicone 0 139 Dia 2 1 4 ID x 2 1 2 OD 05330 003 73 72 9 1 Pre wash Arm 05700 003 75 79 10 4 Cap Threaded 04730 603 12 00 11 1 Pre wash Arm Lower 05700 003 80 96 12 1...
Page 62: ...07610 004 33 05 E 54 PARTS RINSE SYSTEM 1 2 3 4 5 6 7 4 3 3 3 5 5 5 1 8 9 11 10 12 12 13 14...
Page 63: ...47 Hose Specify Length When Ordering 47 Hose Assembly Hose and Fittings 04720 004 19 81 05700 004 48 24 7 1 38 Hose Specify Length When Ordering 38 Hose Assembly Hose and Fittings 04720 004 19 81 057...
Page 64: ...003 06 23 The PRV comes standard on ER units only NOTICE WATER TREATMENT OPTION Replacement Cartridge inspect at least every 6 months RSC 100 Scaltrol System 04730 003 05 76 Must be installed vertical...
Page 65: ...Rack Catch Left 05700 004 29 32 5 7 Rack Catch Right 05700 004 29 33 6 14 Bolt Shoulder 3 8 x 1 4 1 4 20 05306 004 29 34 7 1 Pawl Bar Weldment 05700 004 17 74 8 1 Rack Drive Guide 05700 004 29 36 9 2...
Page 66: ...07610 004 33 05 E 58 PARTS RACK RAILS 1 3 4 2 2 2 3 4 4 4 6 6 5 4 4 7 8 8 7 8 4 9 8 10 11 10 11 8 10 10 10 11 11 11 8 8 8 RackStar 66...
Page 67: ...1 Paddle Switch Pre wash L R Paddle Switch Pre wash R L 05700 004 34 03 05700 004 34 06 10 9 Spacer Rack Guide 05700 011 71 44 11 9 Locknut 1 4 20 Hex with Nylon Insert 05310 374 01 00 Front Rack Rai...
Page 68: ...07610 004 33 05 E 60 PARTS DRIVE ASSEMBLY 10 12 8 7 7 13 6 2 15 4 9 14 17 18 21 23 11 12 13 14 15 16 17 18 19 20 21 22 Drive Assembly 05700 004 29 95 doesn t include Item 17 1 3 5...
Page 69: ...3 8 16 with Nylon Insert Not Shown 05700 004 29 49 05700 004 23 01 05311 004 48 71 05310 004 48 72 11 1 Washer Bonded Sealing 1 4 x 3 4 05311 002 77 79 12 1 Seal V ring 05330 004 52 14 13 1 Motor Plat...
Page 70: ...L ITEM QTY DESCRIPTION PART NUMBER 1 2 Ventilation Cowl 05700 004 34 01 2 2 Ventilation Scoop 05700 004 29 68 3 2 Ventilation Duct Adapter 05700 003 75 73 4 2 Damper Ventilation Scoop 05700 003 74 76...
Page 71: ...rt the rod into the hole at the rear of the Ventilation Cowl 2 Insert the rod into the bracket at the front of the Ventilation Cowl 3 Gently lift the rod at the curtain cut out over and onto the curta...
Page 72: ...ctor switch should be set to H for manual reset DRIVE MOTORS Overloads are specified for 3 phase units only For GE brand MT03 series overloads the process for setting is as follows Determine the FLA f...
Page 73: ...o Right Unhooded Side loader Differences in parts for the 23 Right to Left and both directions of the 30 Side loaders are reflected in the parts list Order lengths of hose or conduit by mea suring the...
Page 74: ...ts a 23 Left to Right Unhooded Side loader Differences in parts for the 23 Right to Left and both directions of the 30 Side loaders are reflected in the parts list Order lengths of hose or conduit by...
Page 75: ...Assembly 05700 004 53 51 8 1 Gutter Pawl Bar 05700 021 66 86 9 1 Guide Block Bottom slotted 05700 011 69 50 10 1 Guide Block Top slotted 05700 011 69 49 11 1 Gasket Drive Gutter 05330 011 68 55 12 1...
Page 76: ...t 3 8 16 with Nylon Insert 05310 011 72 55 5 3 Bolt 3 8 16 x 1 3 4 Hex 05306 011 36 94 6 6 Spacer Pawl Bar Dog 05700 011 71 45 7 2 Screw 1 4 20 x 1 Hex 05305 274 27 00 8 2 Locknut 1 4 20 Hex with Nylo...
Page 77: ...4 04820 011 87 39 6 1 Nipple 3 4 Black Iron 4 Long 04730 907 02 34 7 1 Y strainer Steam 3 4 04730 217 01 32 8 1 Gate Valve Steam 3 4 04820 100 19 00 9 1 Steam Condensate Assembly L R 05700 004 46 56 1...
Page 78: ...V 3 Phase 04540 004 29 77 18 kW 70 F Rise 460 V 3 Phase 04540 004 30 77 18 kW 70 F Rise 600 V 3 Phase 04540 004 55 87 27 kW Energy Recovery 208 V 3 Phase 04540 004 41 68 27 kW Energy Recovery 230 V 3...
Page 79: ...RT NUMBER 12 kW 40 F Rise 208 V 3 Phase 05700 004 48 38 12 kW 40 F Rise 230 V 3 Phase 05700 004 48 41 12 kW 40 F Rise 460 V 3 Phase 05700 004 48 39 12 kW 40 F Rise 600 V 3 Phase 05700 004 91 88 17 2 k...
Page 80: ...l RackStar 44 05700 004 30 44 5 1 Adjustable Foot 05340 011 71 74 6 1 Right Dress Panel L R 05700 004 30 59 Left Dress Panel R L 05700 004 31 92 7 1 Pre wash Hood Dress Panel 05700 004 30 08 8 1 Front...
Page 81: ...mbly HH 05700 004 80 04 05700 004 81 12 3 4 Bearing Flanged Sleeve 03120 004 39 92 4 2 Door Seal 09330 004 17 41 5 10 Screw 10 32 x 1 2 05305 011 44 51 6 1 Door Assembly Pre wash L R Door Assembly Pre...
Page 82: ...07610 004 33 05 E 74 PARTS ENERGY RECOVERY SYSTEM Complete Energy Recovery System Assembly L R 05700 004 39 68 R L 05700 004 40 13 L R HH 05700 004 68 92 R L HH 05700 004 69 04...
Page 83: ...05700 004 36 73 13 1 Collar Vent Scoop 05700 004 36 71 14 1 Curtain 20 1 2 x 19 Curtain HH 20 1 2 x 29 3 4 08415 002 14 41 08415 004 49 64 15 1 Baffle Vent Cowl 05700 002 11 47 16 5 Screw 1 4 20 x 5...
Page 84: ...05700 004 32 75 Strainer Wash Tank 05700 004 29 02 Strainer Pre wash 05700 004 37 61 PARTS MISCELLANEOUS OPTIONS Miscellaneous Parts Options Striker Table Limit Switch Option 05700 002 88 07 Whisker T...
Page 85: ...ut Assignments I1 Wash I2 Cycle I3 Float I4 Rinse I5 Door Chemicals BLK DC RTN RED 24 VDC WHT BLK DC RTN VDCOUT CORRESPONDING CONNECTOR GOING TO DISPLAYPCB B L K B L K R E D W H T B L K G R N LOGIC IN...
Page 86: ...1 L2 N Input Assignments I1 Wash I2 Cycle I3 Float I4 Rinse I5 Chemicals BLK DC RTN RED 24 VDC WHT BLK DC RTN 24 VDC CORRESPONDING CONNECTOR TO DISPLAY PCB PN 05945 004 36 33 B L K B L K R E D W H T B...
Page 87: ...1 L2 N Input Assignments I1 Wash I2 Cycle I3 Float I4 Rinse I5 Chemicals BLK DC RTN RED 24 VDC WHT BLK DC RTN 24 VDC CORRESPONDING CONNECTOR TO DISPLAY PCB PN 05945 004 36 33 B L K B L K R E D W H T B...
Page 88: ...put Assignments I1 Wash I2 Cycle I3 Float I4 Rinse I5 Chemicals BLK DC RTN RED 24 VDC WHT BLK DC RTN 24 VDC CORRESPONDING CONNECTOR TO DISPLAY PCB PN 05945 004 36 33 B L K B L K R E D W H T B L K G R...
Page 89: ...07610 004 33 05 E 81 SCHEMATICS SIDE LOADER...
Page 90: ...05 E This page can be copied and the display templates cut out Lay the cut out over the display and use the Up arrow Down arrow and Select Buttons to locate the hidden programming buttons ADDENDUM DI...
Page 91: ......
Page 92: ...Jackson WWS Inc 6209 N US Hwy 25E Gray KY 40734 USA 1 888 800 5672 www jacksonwws com RackStar Manual 07610 004 33 05 E...
